Module 9 : Process Hazards and Safety Measures in Equipment Design

Lecture 1 : Introduction and Process Hazards

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3. MATERIAL HAZARD

These are mainly because of quantity, concentration, or physical or chemical characteristics of the materials which poses a significant present or potential hazard to human health and safety or to the environment.

1.  Combustible solids, liquids or gases 5. Highly flammable materials
2.  Radioactive materials 6. Reactive materials
3.  Oxidizing materials 7. Corrosive materials
4.  Nuclear materials 8. Toxic materials

Apart from this, some materials react with water to produce a combustible gas and some materials subjects to spontaneous heating, polymerization, or explosive decomposition. It is important to keep such materials separate during both use and storage.

4. PROCESS HAZARD

4.1 General process hazard

The general process hazards might arise due to several factors, some of which are listed below.

  1. a.  Exothermic chemical reaction, in this case there is a strong possibility of the reaction getting out of control.
  2. b.  Endothermic reaction that could react due to an external heat source such as fire or combustion of fuel.

    c.  Material handling and transfer, accounts for the hazard involved in the handling, transfer/pumping and warehousing of the material

    d.  Enclosed or indoor process units, accounts for the additional hazard where the process units preventing dispersion of the escaped vapors.

    e.  Limited access for emergency equipments

    f.  Drainage and spill control, inadequate design of drainage would cause large spills of the flammable material adjacent to process equipment.